Comparison Table: Screen Printing, DTG, and Heat Transfer for Bulk Custom T-Shirts

Guide to Choosing Fabrics for Custom Printed T-Shirts in Bulk: 100% Cotton vs. 50/50 Blend vs. Tri-Blends

When ordering custom printed t-shirts in bulk, one of the most important decisions you’ll make is choosing the right fabric. The material affects comfort, print quality, durability, and overall appearance. Here’s a breakdown of the three most popular fabric options: 100% cotton, 50/50 blends, and tri-blends.

1. 100% Cotton: Classic Comfort and Natural Feel

Pros:
– Soft and breathable: Ideal for everyday wear, especially in warm weather.
– Eco-friendly: Natural fiber, biodegradable, and often available in organic options.
– Excellent printability: Holds screen printing and direct-to-garment (DTG) inks well, producing vibrant, crisp designs.
– Widely available: Found in a variety of weights and styles (e.g., lightweight, heavy cotton).

Cons:
– Prone to shrinking: May shrink after washing, especially if not pre-shrunk.
– Less durable over time: More likely to wear out, fade, or develop holes with frequent use and washing.
– Wrinkles easily: Requires more ironing or care for a polished look.

Best For: Events, retail brands, or promotional campaigns where comfort and a natural feel are top priorities.

2. 50/50 Blend: Cotton-Polyester Balance

A 50/50 blend combines equal parts cotton and polyester, offering a middle ground between comfort and durability.

Pros:
– Durable and long-lasting: Resists pilling and wear better than 100% cotton.
– Less shrinkage: Holds shape well after multiple washes.
– Affordable: Often priced lower than tri-blends or premium cotton.
– Good print surface: Works well with plastisol and water-based inks; slight sheen can enhance certain designs.

Cons:
– Less breathable: Polyester can trap heat, making it less ideal for hot climates.
– Slight synthetic feel: Not as soft or natural as 100% cotton or tri-blends.
– Prone to static and odor retention: May hold odors more than cotton and generate static cling.

Best For: Corporate giveaways, school events, or high-volume orders where cost and durability are key.

3. Tri-Blend: Softness Meets Performance

Tri-blend fabrics typically consist of cotton, polyester, and rayon (e.g., 50% poly, 25% cotton, 25% rayon), offering a luxurious, vintage feel.

Pros:
– Ultra-soft and smooth: Feels broken-in from day one—great for premium apparel.
– Excellent drape: Flattering fit with a slightly slimmer, modern silhouette.
– Vintage aesthetic: Fades beautifully over time, giving a worn-in, stylish look.
– Good moisture-wicking: Polyester and rayon improve moisture management.

Cons:
– Higher cost: More expensive than cotton or 50/50 blends.
– Delicate fabric: Can be less durable under heavy use or rough washing.
– Printing considerations: May require pretreatment for DTG printing; colors can appear slightly muted.

Best For: Fashion-forward brands, boutique apparel, or high-end promotional merch where premium quality is essential.

Final Tips for Bulk Orders

• Consider your audience: Choose fabric based on how and where the shirts will be worn.
• Match fabric to printing method: DTG works best on cotton-heavy fabrics; plastisol is more flexible across blends.
• Request samples: Always order swatches or sample shirts to test comfort, fit, and print quality.
• Think about care instructions: More delicate fabrics like tri-blends may require gentle washing—communicate this to recipients.

By understanding the strengths and limitations of 100% cotton, 50/50 blends, and tri-blends, you can select the ideal fabric for your custom printed t-shirts—balancing comfort, cost, and quality for your bulk order.

How to Get the Best Price on Custom Printed T-Shirts in Bulk

Ordering custom printed t-shirts in bulk is a cost-effective way to outfit teams, promote your brand, or sell merchandise. However, getting the best price requires strategy and preparation. Here’s how to maximize your savings and ensure quality results.

Leverage Bulk Quantity Breaks

One of the most effective ways to reduce the per-unit cost of custom t-shirts is by taking advantage of quantity breaks offered by printers.

• Understand Tiered Pricing: Most screen printing and direct-to-garment (DTG) companies offer lower prices per shirt as your order size increases. Common tiers include 25, 50, 100, 250, and 500+ units. For example, 50 shirts might cost $8 each, while 100 shirts drop to $6 each.
• Order Just Beyond the Breakpoint: If the next pricing tier starts at 100 units, and you only need 90, consider ordering 100 to benefit from the lower rate. The extra 10 shirts could serve as backups or future inventory.
• Consolidate Designs When Possible: If you’re ordering multiple designs, ask your printer if pricing is based on total quantity or per design. Some printers charge setup fees per design, so consolidating styles or colors can save money.

Optimize Your Artwork for Cost Efficiency

High-quality artwork ensures professional results, but smart design choices can also lower production costs.

• Simplify Your Design: Fewer colors mean lower screen printing costs. Each color requires a separate screen and setup. Aim for 1–3 colors to keep prices down.
• Use Vector Files: Provide artwork in vector format (e.g., .AI, .EPS, or .SVG) for crisp, scalable prints. Raster files (like .JPG or .PNG) can pixelate when enlarged, leading to rework fees.
• Follow Print Area Guidelines: Avoid printing too close to seams or edges, as this may require special setups. Stick to standard print locations (center chest, back, or sleeve) to avoid added charges.
• Limit Print Locations: Printing on both the front and back increases labor and material costs. If possible, choose a single location per shirt.
• Proof Carefully Before Approval: Review digital proofs thoroughly. Mistakes caught early prevent costly reprints or delays.

Additional Tips to Save on Bulk Orders

• Choose Affordable Blank Apparel: The shirt itself impacts cost. Basic cotton styles are cheaper than premium or specialty blends. Select a quality level that matches your budget and use case.
• Get Multiple Quotes: Compare pricing from at least 3–5 reputable printers. Look beyond the lowest price—consider turnaround time, customer service, and minimums.
• Plan Ahead: Rush orders often incur fees. Place your order well in advance to qualify for standard production times and avoid surcharges.
• Ask About Bundles or Promotions: Some printers offer discounts on specific shirt brands, free design services, or waived setup fees for first-time customers.

By combining strategic ordering, smart design choices, and careful vendor selection, you can achieve significant savings while getting high-quality custom t-shirts for your bulk order.